Coolbelt Helmet Cooling System

OM-235 368B 2010−03 ®

t CoolBelt Helmet Cooling System

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TABLE OF CONTENTS

SECTION 1 − HELMET COOLER SAFETY PRECAUTIONS − READ BEFORE USING...... 1 1-1. Symbol Usage...... 1 1-2. Hazards ...... 1 SECTION 2 − BATTERY SAFETY PRECAUTIONS − READ BEFORE USING...... 3 2-1. Symbol Usage...... 3 2-2. Hazards ...... 3 SECTION 3 − HELMET COOLING SYSTEM...... 5 3-1. Helmet Cooling System Specifications...... 5 3-2. Installing Headgear And Shroud...... 6 3-3. Charging The Battery...... 7 3-4. Installing The Battery...... 8 3-5. Installing The Filter...... 9 3-6. Attaching The Connecting Hose...... 10 3-7. Operating The Controls...... 11 3-8. Checking The Helmet Cooling System Before Use...... 12 3-9. Putting On The Helmet Cooling System...... 13 3-10. Changing Hose Length...... 14 3-11. Replacing Belt...... 15 3-12. Maintenance And Storage...... 16 3-13. Helmet Cooling System Troubleshooting...... 16 SECTION 4 − ADJUSTING HEADGEAR...... 18 SECTION 5 − PARTS LIST...... 19 SECTION 6 − LIMITED WARRANTY...... 20 SECTION 1 − HELMET COOLER SAFETY PRECAUTIONS − READ BEFORE USING

Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Helmet Cooler 2009−11

DANGER! − Indicates a hazardous . Indicates special instructions. situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation This group of symbols means Warning! Watch which, if not avoided, could result in Out! ELECTRIC SHOCK, MOVING PARTS, death or serious injury. The possible and HOT PARTS hazards. Consult symbols hazards are shown in the adjoining and related instructions below for necessary symbols or explained in the text. actions to avoid the hazards. NOTICE − Indicates statements not related to personal injury. 1-2. Hazards

Only qualified persons should install, operate, maintain, and repair this unit.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section. D Use only genuine replacement parts from the manufacturer. D Perform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local codes.

HELMET COOLER MISUSE can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Read and follow these instructions and the safety labels carefully. This product is intended for use as a cooling device only. It is not a respiratory protective device and does not protect the user from airborne contaminants. Have an industrial hygienist test the air in your facility to determine if respiratory protection is required to provide adequate protection from contaminants in your environment. With cooling system-equipped helmet on your head and cooling system operating, also test the air inside the helmet to determine if respiratory protection is required. If you have questions about the type of respiratory protection equipment required, consult your safety director and an Industrial Hygienist. D Do not use this product where there is danger of fire or explosion. D Do not use this product in windy conditions or negative pressure inside the hood may draw in contaminants from the outside air. D Do not use this product without a properly installed spark guard unless the unit is designed and intended to be used without one. Without the spark guard (on applicable products), welding sparks may ignite the filter or damage the filter. D This product does not supply oxygen. Do not use this product where oxygen levels are 19.5% or lower, where contaminant levels are unknown or are immediately dangerous to life or health (IDLH), or where the contaminant levels exceed the equipment specifications. D Do not enter a work area until you are sure the equipment is correctly assembled, working properly, and properly worn. OM-235 368 Page 1 D Before each use, inspect the equipment for damage and verify it operates properly. D Dangerous contaminants may not smell or be visible. Leave the area immediately if you notice the following: . . . Breathing becomes difficult. . . . You experience dizziness, impaired vision, or eye, nose, or mouth irritation. . . . The equipment is damaged. D Do not repair, modify, or disassemble this product or use with parts or accessories not supplied by the manufacturer. D Do not operate unit without properly installed filter(s). Replace damaged or clogged filters. Do not wash or reuse filters. Do not clean filters by tapping or with compressed air or filter elements may be damaged. D Do not restrict or alter helmet cooler air flow. Do not block air inlet or outlet. Be sure safety glasses, hair, weld cap, and other objects do not block air flow. D This product contains electrical parts which have not been evaluated as an ignition source in flammable or explosive atmospheres by MSHA/NIOSH.

OM-235 368 Page 2 SECTION 2 − BATTERY SAFETY PRECAUTIONS − READ BEFORE USING

Protect yourself and others from injury — read and follow these precautions.

2-1. Symbol Usage Small Batt 2009−11

Only qualified persons should install, operate, maintain, and repair this unit. FIRE OR BATTERY EXPLOSION hazard.

D During operation keep everyone, especially children, away. D Do not install or place charger on, over, or near combustible surfaces. D Do not charge battery near flammables. D Examine the battery before first use. Return battery to the manufacturer if battery is damaged, dirty, or emits an unusual odor. D Use battery only with equipment with which it was supplied. Replace battery only with battery specified in Owner’s Manual. Use of another battery may present a risk of fire or explosion. D Keep battery dry. D Do not use or store the battery in extremely hot or humid conditions. See the Owner’s Manual for specific operating and storage information. D Keep battery away from fire, out of direct sunlight, and away from other sources of heat. D Do not use or charge the battery if it has been dropped or damaged. D Do not open, puncture, repair, disassemble, or modify the battery. D Charge battery only with supplied charger in an open, well−ventilated location out of direct sunlight and according to supplied instructions. D Do not overcharge a battery or charge battery longer than specified (if charger is not equipped with automatic shutoff). See the Owner’s Manual for specific information on battery charging. D Do not charge battery by connecting directly to AC receptacle. Do not connect battery charger to automobile auxiliary power receptacle. D Do not connect (short circuit) battery terminals to each other. Do not allow tools, conductive materials, or other objects to touch both battery terminals at the same time. D Do not weld on battery or fasten any objects to battery. D Do not heat battery in a microwave oven or any other heating device. D Keep battery away from sources of high voltage. D Do not expose battery to static electricity. D Do not use or mix battery with damaged or worn out batteries, or other types of batteries. OM-235 368 Page 3 BATTERY ACID can BURN SKIN and EYES.

D Replace damaged battery. D Do not touch materials from inside a damaged battery. D Flush eyes and skin immediately with water.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s Manual carefully before before using the battery or battery charger. Read the safety information at the beginning of the manual and in each section. D Dispose of battery according to local, state, and federal requirements. Do not dispose of battery in fire or water. D Contact the equipment manufacturer if you have any questions about the battery.

OM-235 368 Page 4 SECTION 3 − HELMET COOLING SYSTEM

Read and follow these instructions and the safety labels carefully. This product is intended for use as a cooling device only. It is not a respiratory protective device and does not protect the user from airborne contaminants. Have an industrial hygienist test the air in your facility to determine if respiratory protection is required to provide adequate protection from contaminants in your environment. With cooling system-equipped helmet on your head and cooling system operating, also test the air inside the helmet to determine if respiratory protection is required. If you have questions about the type of respiratory protection equipment required, consult your safety director and an Industrial Hygienist. . Use the cooling system only with compatible Miller welding helmets (see Specifications below). See the welding helmet Owner’s Manual for information on helmet operation.

The helmet cooling system draws in air and blows it into the welding helmet shroud through a flexible connecting hose. The system must include and/or be used with the equipment listed below: D Helmet and head shroud D Connecting hose D Blower assembly with filtration system (spark guard and filter) D Belt assembly D Battery charger The respirator equipment operates at temperatures from 32 to 104° F and provides air flow of 6 CFM (low speed) to 7 CFM (high speed) under normal conditions. Battery life is reduced when the unit is used in a dirty environment. (The blower assembly Batt light goes on when battery power is low.) 3-1. Helmet Cooling System Specifications

Application Fits Most Miller Welding Helmets: Elite, Digital Elite, ® ® MP-10, Performance , Pro-Hobby , Titanium, XLix

Size (Blower Assembly) 6-5/8 x 6-1/2 x 2-3/8 in (169.4 x 164.1 x 57.4 mm) Weight (Blower Assembly w/Battery, Fil- 25.6 oz. (726 g) ter, Belt, Hose)

Filter Use Miller Filter Only (Miller Part No. 245 233) . Filter is required for proper operation of equipment, but does not provide respiratory protection. Air Flow Low Speed: 6+ CFM (170+ LPM) minimum High Speed: 7 CFM (200 LPM)

Operating Temperature −4° to 140° F (-20° to 60° C) Storage Temperature 23° to 131° F (−5° to 55° C) Battery Type Rechargeable Lithium Battery Charging Time Four Hours (typical) Battery Life 500 Charges Run Time At High Speed: 4-1/2 Hours Run Time At Low Speed: 6 Hours (Run Time Dependent On Air Flow Rate And Filter Load.) Belt Size Up To 48 in. (122 cm) Shroud Service Life Replace After 50 Washings OM-235 368 Page 5 3-2. Installing Headgear And Shroud

. After installing shroud, 1 make sure there are no gaps between shroud and helmet edge. 1 Standard Headgear 2 Velcro Strip 3 Cooling System Headgear 4 Shroud 5 Velcro On Shroud Remove knobs, o−rings, and washers from standard headgear. Remove headgear. 2 Use damp towel to clean area inside helmet where Velcro® will be installed. Allow cleaned area to dry. Remove backing from Velcro. Install Velcro strip 5/8 in. (1.5 cm) from edge of quick release Elite and Titanium helmets. For all other helmets, install Velcro 3/4 in. (2 cm) from edge of helmet. 3 4 Position cooling system headgear in helmet. Install headgear mounting screw in headgear bottom hole (quick release Elite and Titanium helmets) or top hole (all other helmets). Secure headgear with knobs, o−rings, and washers. Use bottom hole for Align Velcro on shroud with Vel- quick release Elite cro strip inside helmet. Press the and Titanium hel- Velcro surfaces securely to- mets. Use top hole gether. for all other helmets. 5 Check for gaps between shroud and helmet. Reposition shroud and Velcro if necessary.

. Remove shroud from helmet when using helmet with the cooling system turned off.

. See Section 4 for headgear adjustment information.

Ref. 231 425 / Ref. 804 111

OM-235 368 Page 6 3-3. Charging The Battery

. Charge battery only used for three months 3 120 Volt AC Receptacle with supplied charger or longer, fully dis- (Not Shown) charge and recharge in an open, well−ven- Remove battery from blow- tilated location. battery twice (for optim- al battery life). er assembly (Section 3-4). . Do not allow battery Connect charger cord to to get wet. Do not at- . Dispose of battery at a battery terminal. Connect tempt to open the bat- designated collection charger to 120 volt AC re- tery case. facility. ceptacle. The charger red light goes . Keep battery away . Battery charging stops from fire or heat. on when battery is being when battery is fully charged. When fully charged. . Charge battery before charged, the charger green first use or if battery has 1 Battery Terminal light goes on. Charging nor- not been used for five mally takes about four days. If battery was not 2 Battery Charger hours.

OM-235 368 Page 7 3-4. Installing The Battery

. Do not allow battery to get wet. Do not attempt to open the battery case.

2 1 . Keep battery away from fire or heat. 1 Battery 2 Blower Assembly Slide battery into blower assembly until it locks into position. 3 Battery Release To remove battery, lift battery release while pulling battery away from blower assembly.

OM-235 368 Page 8 3-5. Installing The Filter

. Do not use the helmet cooling system without the spark guard screen and filter installed. . Replace damaged or dirty filter. Do not wash filter, clean 1 with compressed air, reverse 2 filter, or reuse dirty filter.

. Filter is required for proper operation of equipment, but does not

FF ON / O provide respiratory protection. 1 Cover Release 2 Spark Guard Screen 3 Filter Push on release to open cover. Install screen in cover. Install filter in recessed area on blower housing.

. Install filter in recessed area on blower housing, not in the cover. Close cover.

OM-235 368 Page 9 3-6. Attaching The Connecting Hose

. Be sure connecting hose is properly installed or cooler will not work properly. 1 Release Buttons Align hose connector (round end) with outlet on blower assembly. Press release buttons and slide hose connector over outlet until it locks in position 1 2 Locking Tab Push hose connector (rectangular end) into helmet air inlet until hose locks in position. (Locking tab should be on outside of helmet air inlet.

. Do not insert hose locking tab into helmet inlet. Locking tab should be on outside of helmet air inlet.

OM-235 368 Page 10 3-7. Operating The Controls

. Read and follow these instructions and the safety labels carefully. This product is intended for use as a cooling device only. It is not a respiratory protective device and does not protect the user from airborne 4 contaminants. Have an indus- 2 3 trial hygienist test the air in BATT your facility to determine if respiratory protection is required to provide adequate protection from contaminants in your environment. With LOW HIGH cooling system-equipped helmet on your head and cooling 1 ON/OFF system operating, also test the FLOW air inside the helmet to deter- (LO/HI) mine if respiratory protection is required. If you have questions about the type of respiratory protection equipment required, consult your safety director and an Industrial Hy- gienist. . Do not restrict or alter helmet cooling system air flow. Be sure safety glasses, hair, weld cap, and other objects do not block air flow. 1 On/Off Button 2 Low Speed Indicator 3 High Speed Indicator 4 Battery Level Indicator To Start: Press On button for 1−2 seconds until alarm sounds and blower starts. The blower always starts at the low speed. Press the On/Off button to switch between Low and High speeds. To Stop: Press Off button for 2 − 3 seconds until the audible alarm and the blower stop. The Battery Level indicator lights when batter power is low. See Sec- tion 3-3 for battery charging information.

. The Battery Level indicator lights for several seconds after blower is started.

OM-235 368 Page 11 3-8. Checking The Helmet Cooling System Before Use

. Read and follow . Do not restrict or alter 3 Battery (Sections 3-3 these instructions helmet cooling sys- And 3-4) and the safety labels tem air flow. Be sure Verify the battery is fully carefully. This safety glasses, hair, charged and securely in- product is intended weld cap, and other stalled in the blower assem- for use as a cooling objects do not block bly. device only. It is not a air flow. 4 Air Flow (Section 3-7) respiratory protec- Turn on blower assembly tive device and does Before using the helmet and test air flow at low and not protect the user cooling system, check the high speeds. from airborne con- following items: taminants. Have an 5 Shroud (Section 3-2) industrial hygienist Inspect the shroud and re- test the air in your fa- 1 Filter And Spark Guard (Section 3-5) place if damaged. See cility to determine if Troubleshooting (Section respiratory protec- 3-13) if air is not being sup- tion is required to . Filter is required for plied to front of helmet. provide adequate proper operation of protection from con- equipment, but does Put on helmet and adjust taminants in your en- not provide respiratory helmet so helmet fits snugly vironment. With cool- protection. on head. Verify shroud is ing system-equipped properly installed on hel- helmet on your head Verify the filter and spark met. and cooling system guard are undamaged, . See the welding helmet operating, also test properly assembled, and the air inside the hel- Owner’s Manual for securely connected to the met to determine if helmet adjustment in- blower assembly. respiratory protec- formation. tion is required. If you 6 Fabric Shroud have questions about 2 Flexible Hose (Section (Section 3-2) 3-6) the type of respirato- Inspect the shroud and re- ry protection equip- place if damaged. See Be sure the hose is undam- ment required, con- Troubleshooting (Section sult your safety direc- aged and properly con- 3-13) if air is not being sup- nected to the blower as- tor and an Industrial plied to shroud. Hygienist. sembly and shroud. . See Section 4 for headgear adjustment information.

OM-235 368 Page 12 3-9. Putting On The Helmet Cooling System

. Do not use the equipment belt or straps as a safety har- ness. Place blower assembly against lower back with hose extending up- wards. Fasten belt around waist. Adjust belt so unit rests comfort- ably against lower back. Put on helmet and adjust helmet so helmet fits snugly on head. Tighten shroud drawstring to establish a tight seal around head.

247 603

OM-235 368 Page 13 3-10. Changing Hose Length

The hose can be shortened to im- prove comfort or meet personal requirements. 1 Connector (Blower End) 2 Collar

2 Carefully pry collar away from con- 1 nector. Do not remove collar from hose. Cut hose to desired length. Turn connector counterclockwise into hose. Push collar on connector.

Tools Needed:

OM-235 368 Page 14 3-11. Replacing Belt

1 Screw 2 Body Mount 3 Belt 4 Loops 1 Remove screw and turn body ° mount 90 counterclockwise. Re- move belt from mount. Install new new belt as shown. Reassemble mount and tighten screw.

Tools Needed:

phillips

OM-235 368 Page 15 3-12. Maintenance And Storage

Replace damaged or dirty filter. Do not wash filter, clean with compressed air, reverse filter, or reuse dirty filter.

Never use solvents or abrasive cleaning solutions to clean the helmet cooling system . Keep water and other fluids out of blower assembly.

Replace shroud after 50 washings. Shroud loses its fire retardant properties with re- peated washing. For best performance clean the equipment after each use. Use a soft cloth dampened with a mild soap and water solution to wipe all external surfaces clean. Allow to air dry. Product usage, workplace contamination levels, and other factors affect the life of the filter. Replace filter if air flow is reduced due to a dirty filter (see Section 3-5). Inspect connecting hose and replace if damaged or if inside of hose is extremely dirty. If the helmet cooling system will not be used for an extended period, remove the filter and battery and store them in a clean, dry, cool place free of solvent-based vapors.

3-13. Helmet Cooling System Troubleshooting

Trouble Remedy

Blower does not supply air Press On/Off button. to helmet.

Dead battery; recharge battery (see Section 3-4).

Verify battery is properly connected to blower body.

Verify hose is properly connected.

Remove blockage from blower outlet and hose.

Blower cannot be turned Press and hold On/Off button for two to three seconds. Off.

Blower runs for short time Be sure battery is properly connected to battery charger. even though battery is fully charged.

Replace filter.

Replace battery.

Replace charger.

Battery Level Indicator Charge or replace the battery. The blower will operate for about 20 light is On. minutes after the light goes on. (The Battery Level indicator lights for several seconds after blower is started.)

OM-235 368 Page 16 Battery run time is too Replace battery. short.

Check filter and replace if necessary (see Section 3-5). A clogged filter element reduces battery life.

Air supplied to helmet Continue wearing the helmet cooling system and leave the con- smells and tastes unusual; taminated area immediately. Check contamination level of filter, eyes and throat irritation. and replace filter if necessary.

Check hose connections to blower and shroud.

Have Safety Director and an Industrial Hygienist determine if you are using the proper equipment for the work environment.

Blower supplies insuffi- Check hose connections to blower and shroud. cient air to helmet.

Remove blockage from blower outlet and/or hose.

Check filter and replace if necessary (see Section 3-5). A clogged filter element reduces battery life.

OM-235 368 Page 17 SECTION 4 − ADJUSTING HEADGEAR

. There are four headgear adjust- ments: headgear top, tightness, angle adjustment, and distance adjustment. 1 Headgear Top Adjusts headgear for proper depth on the head to ensure correct bal- 1 ance and stability. 3 2 Headgear Tightness To adjust tightness, rotate the adjusting knob left or right to desired position.

. If adjustment is limited, it may be necessary to remove the comfort cushion. 3 Distance Adjustment Adjusts the distance between the face and the lens. To adjust, loosen both outside tension knobs and press inward to free from adjustment slots. Move forward or back to desired position and retighten. (Both sides must be equally positioned for proper vision.) 4 Angle Adjustment Four pins on the right side of the 2 4 headband top provide adjustment for the forward tilt of the helmet. To adjust, loosen the right outside tension adjustment knob then lift on the control arm tab and move it to the desired position. Retighten tension adjustment knob.

. When using the back distance adjustment positions, only the back three angle adjustment pins can be used.

804 118

OM-235 368 Page 18 SECTION 5 − PARTS LIST

Î 5 2 4 1

BATTH OWHIG ON/OFF

11 9 10

Ref. 805 193 Figure 5-1. CoolBelt Helmet Cooling System Item Part No.No. Description Quantity

Figure 5-1. CoolBelt Helmet Cooling System

1...... 245235 ...... Headgear (Includes) ...... 1 ...... Replacement O-rings (5 Per Pkg.) ...... 1 ...... 770249 ...... Fabric Headband ...... 1 2...... 245236 ...... Head Shroud ...... 1 3...... 245232 ...... Belt ...... 1 4...... 245231 ...... Hose Assembly ...... 1 5...... 246964 ...... Cover, Hose ...... 1 6...... 246965 ...... Blower Unit ...... 1 7...... 245233 ...... Filter ...... 1 8...... 247921 ...... Spark Arrestor ...... 1 9...... 245234 ...... Filter Cover ...... 1 10...... 245238 ...... Charger ...... 1 11...... 245237 ...... Battery, Blower ...... 1 OM-235 368 Page 19 SECTION 6 − LIMITED WARRANTY

LIMITED WARRANTY – Subject to the terms and conditions below. Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail pur- chaser that the new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OR MERCHANTABILITY AND FITNESS. The helmet cooling system is warranted for one year from the date of purchase. Proof of purchase is required for warranty transactions so it is imperative that a copy of the original invoice or sales receipt be retained.

For warranty transactions, contact your Miller Distributor.

Effective January 1, 2010

OM-235 368 Page 20 Notes

Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.

OM-235 368 Page 21 Visit our website at www.MillerWelds.com

Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA